Vacuum insulated door structure for an appliance incorporating a dispenser structure

ABSTRACT

A door panel for a refrigerating appliance includes an inner liner. An outer wrapper is attached to the inner liner and defines an insulating structure with an insulating cavity disposed therein. An insulating material is defined within the insulating cavity. A dispenser structure is defined within a central portion of the inner liner and the outer wrapper. The dispenser structure defines an insulated dispenser portion therein. A dispenser conduit extends from an interior area disposed above the dispenser structure to an external dispensing cavity and passing through the insulated dispenser portion.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a divisional of U.S. patent application Ser.No. 17/130,554 filed Dec. 22, 2020, entitled VACUUM INSULATED DOORSTRUCTURE FOR AN APPLIANCE INCORPORATING A DISPENSER STRUCTURE, now U.S.Pat. No. 11,435,130, which is divisional of U.S. patent application Ser.No. 16/221,997 filed Dec. 17, 2018, entitled VACUUM INSULATED DOORSTRUCTURE FOR AN APPLIANCE INCORPORATING A DISPENSER STRUCTURE, now U.S.Pat. No. 10,907,882, the entire disclosures of which are herebyincorporated herein by reference.

FIELD OF THE DEVICE

The device is in the field of vacuum insulated structures forappliances, and more specifically, a vacuum insulated structure for adoor of an appliance that incorporates a structure for dispensing waterand ice.

SUMMARY

In at least one aspect, a door panel for a refrigerating applianceincludes an inner liner. An outer wrapper is attached to the inner linerand defines an insulating structure with an insulating cavity disposedtherein. An insulating material is defined within the insulating cavity.A dispenser structure is defined within a central portion of the innerliner and the outer wrapper. The dispenser structure defines aninsulated dispenser portion therein. A dispenser conduit extends from aninterior area disposed above the dispenser structure to an externaldispensing cavity and passing through the insulated dispenser portion.

In at least another aspect, a door panel for a refrigerating applianceincludes an inner liner coupled with an outer wrapper and defining aninsulating cavity therein. An interior perimeter is defined within theouter wrapper. An insulating material is defined within the insulatingcavity. The insulating cavity defines an at least partial vacuum. Adispenser structure is disposed proximate the interior perimeter. Thedispenser structure defines an insulated dispenser portion therein. Thedispenser structure further defines an external dispensing cavitydefined within the interior perimeter and extending rearward of theinterior perimeter. A dispenser conduit extends from an interior areadisposed above the dispenser structure to the external dispensing cavityand passing through the insulated dispenser portion.

In at least another aspect, a method for forming a door panel for anappliance includes forming a vacuum insulated structure having an innerliner, an outer wrapper and a sealed internal aperture extending throughthe inner liner and the outer wrapper. A dispensing assembly is attachedto the vacuum insulated structure at the sealed internal aperture. Thesealed internal aperture includes a plurality of attachment tabs thatextend from each of the inner liner and the outer wrapper. Thedispensing assembly is secured to the plurality of attachment tabs viamechanical fasteners. The plurality of attachment tabs includes fastenerreceptacles that receive a corresponding fastener and maintain thecorresponding fastener separate from an insulating cavity of the vacuuminsulated structure.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of an appliance incorporating anaspect of the vacuum insulated door incorporating the dispenserstructure;

FIG. 2 is a front perspective view of the appliance of FIG. 1 showingthe doors in an open position;

FIG. 3 is a schematic cross-sectional view of a vacuum insulated doorstructure having a deep drawn section that forms the dispenserstructure;

FIG. 4 is an enlarged schematic cross-sectional view of the doorstructure of FIG. 3 taken at area IV, and showing a trim breaker thatforms a dispenser conduit of the dispenser structure;

FIG. 5 is a schematic cross-sectional view of a vacuum insulated doorstructure, and showing the dispenser structure as a separate dispenserassembly that is attached to the main body of the door structure;

FIG. 6 is a schematic perspective view of an aspect of the separatedispenser assembly being attached to the vacuum insulated doorstructure;

FIG. 7 is a schematic cross-sectional view of an aspect of the separatedispenser assembly being attached to the remainder of the vacuuminsulated door structure;

FIG. 8 is a linear flow diagram illustrating a method for forming a doorpanel having a dispenser structure; and

FIG. 9 is a linear flow diagram illustrating a method for forming a doorpanel having a dispenser structure.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1 . However, itis to be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

With respect to FIGS. 1-7 , reference numeral 10 generally refers to adispenser structure that can be incorporated as part of a vacuuminsulated door panel 12, where the dispenser structure 10 can at leastpartially receive a water dispensing assembly 14 and an ice makingassembly 16. The dispenser structure 10 also includes a path throughwhich water and ice pieces can be dispensed into a dispenser well 18.

According to various aspects of the device, as exemplified in FIGS. 1-7, a door panel 12 for a refrigerating appliance 20 can include an innerliner 22 and an outer wrapper 24 that is attached to the inner liner 22.The inner liner 22 and outer wrapper 24 define an insulating structure26 with an insulating cavity 28 disposed therein. An insulating material30 is disposed within the insulating cavity 28 that is formed betweenthe inner liner 22 and the outer wrapper 24 and is maintained at an atleast partial vacuum 32. In this manner, the inner liner 22, outerwrapper 24 and insulating material 30 form the vacuum insulatingstructure 26 for the door panel 12. A dispenser structure 10 is definedwithin a central portion 34 of the inner liner 22 and the outer wrapper24. The dispenser structure 10 can define an insulated dispenser portion36 within an interior space of the dispenser structure 10. A dispenserconduit 40 is included within the dispenser structure 10 and extendsfrom an interior area 42 disposed above the dispenser well 18 to anexternal dispenser well 18. In this manner, the dispenser conduit 40passes through the insulated dispenser portion 36 of the dispenserstructure 10. The interior area 42 disposed above the dispenser well 18is typically positioned proximate the inner liner 22 and also above thedispenser structure 10 that is attached to the insulating structure 26of the door panel 12. The dispenser well 18 is positioned proximate theouter wrapper 24 and forms a space that can be conveniently accessed bya user of the refrigerating appliance 20 for receiving dispensed wateror ice pieces or for placing a container to be filled with water and/orice.

Referring now to FIGS. 3 and 4 , the dispenser well 18 for theinsulating structure 26 can include a deep drawn portion 50 of the innerliner 22, the outer wrapper 24 and the insulating cavity 28 definedtherebetween. In such an embodiment, the dispenser conduit 40 is definedby an interior trim breaker 52 that is disposed through part of the deepdrawn portion 50 of the inner liner 22 and the outer wrapper 24. In thismanner, the interior trim breaker 52 extends through the insulatingcavity 28 to define the dispenser conduit 40 that extends fully throughthe insulating structure 26 for the door panel 12. The interior trimbreaker 52 is fixedly coupled with each of the inner liner 22 and theouter wrapper 24. Using the interior trim breaker 52, the insulatingstructure 26 of the door panel 12 can be maintained as a single andcontinuous insulating cavity 28 that can be maintained at an at leastpartial vacuum 32. Accordingly, the insulating cavity 28 of the doorpanel 12 includes the insulated dispenser portion 36 that is defined bythe deep drawn portion 50 formed by the inner liner 22 and outer wrapper24 of the door panel 12.

Referring again to FIGS. 3 and 4 , the interior trim breaker 52 caninclude a liner channel 60 that receives interior liner edges 62 of theinner liner 22. The interior trim breaker 52 can also include a wrapperchannel 64 that is configured to receive interior wrapper edges 66 ofthe outer wrapper 24. In this manner, the interior trim breaker 52 cancooperate with the inner liner 22 and the outer wrapper 24 to seal theconduit opening 68 defined through each of the inner liner 22 and theouter wrapper 24 to form the dispenser conduit 40 for the dispenserstructure 10.

According to various aspects of the device, the interior trim breaker 52can be made of various materials that can include, but are not limitedto, plastic, metal, glass, ceramic materials, polymer materials,combinations thereof, and other similar materials that are adapted formaintaining airtight seal or a substantially airtight seal within astructure. It is contemplated that the interior trim breaker 52 can bewelded, adhered, attached, or otherwise coupled to each of the innerliner 22 and outer wrapper 24 to form the dispenser conduit 40 withinthe dispenser structure 10. The interior trim breaker 52 can also bepositioned so that the interior trim breaker 52 is located within a topportion 70 of the dispenser well 18 and is substantially concealed bythe outer wrapper 24 and also by various components of the dispenserstructure 10. These various components can include, but are not limitedto, dispenser paddles 72, trim assemblies, lighting assemblies, or othersimilar components of a dispenser system 74 for the appliance 20.

Referring again to FIGS. 3 and 4 , the dispenser conduit 40 and theinterior trim breaker 52 can include various shapes and sizes. By way ofexample, and not limitation, the interior trim breaker 52 and thedispenser conduit 40 can be round, oval, rectilinear, irregularlyshaped, combinations thereof, or other similar shape that can be used toprovide for the dispensing of water and ice pieces therethrough. Theshape of the dispenser conduit 40 and the interior trim breaker 52 canvary depending upon the configuration of the particular ice makingassembly 16 and water dispensing assembly 14 for dispensing of water andice pieces therethrough. The size of the dispenser conduit 40 and theinterior trim breaker 52 can also vary depending upon the configurationof the particular ice making assembly 16 being attached thereto and thesize and shape of the ice pieces being delivered therethrough.

Referring again to FIGS. 3 and 4 , positioning of the interior trimbreaker 52 for attaching to the inner liner 22 and outer wrapper 24 isadapted to conceal most, if not all, of the interior trim breaker 52. Inthis manner, the outer wrapper 24 can include turned flanges 80 that aredirected away from the dispenser well 18. Accordingly, the attachmentbetween the interior trim breaker 52 and the outer wrapper 24 is atleast partially defined within the insulating cavity 28 between theinner liner 22 and the outer wrapper 24. Similarly, the inner liner 22can also include a turned flange 80 that is adapted to engage the linerchannel 60 of the interior trim breaker 52. It is contemplated that theturned flange 80 of the inner liner 22 can extend away from thedispenser well 18 or toward the dispenser well 18, depending upon theconfiguration of the interior trim breaker 52. Where the turned flange80 of the inner liner 22 is angled toward the dispenser well 18, theinterior trim breaker 52 is positioned entirely between, orsubstantially between, the inner liner 22 and the outer wrapper 24 suchthat the liner channel 60 and wrapper channel 64 of the interior trimbreaker 52 face opposite directions for receiving the turned flanges 80of the inner liner 22 and outer wrapper 24.

It is also contemplated that the turned flange 80 of the inner liner 22can be directed away from the dispenser well 18, as illustrated in FIGS.3 and 4 . In such a configuration, the interior trim breaker 52 can beattached to the inner liner 22 and outer wrapper 24 by linearlyinserting the interior trim breaker 52 through the opening 122 thatforms the dispenser conduit 40. Where the liner channel 60 and wrapperchannel 64 of the interior trim breaker 52 are oriented in the samedirection, the interior trim breaker 52 can be inserted from above thedispenser well 18 to form a type of plug that seals the transitionbetween the inner liner 22 and outer wrapper 24 to form the dispenserconduit 40. In these configurations, it is contemplated that theinterior trim breaker 52 is substantially concealed from view, whenviewed from the dispenser well 18.

Referring now to FIGS. 5-7 , the dispenser structure 10 for the doorpanel 12 can be in the form of a separate dispenser assembly 90 that isattached to the central portion 34 of the inner liner 22 and the outerwrapper 24. In such an embodiment, the dispenser assembly 90 includesthe dispenser conduit 40 therein. The inner liner 22 and outer wrapper24 cooperatively define an aperture 92 within the central portion 34.The aperture 92 includes at least one attachment tab 94 that coupleswith the dispenser assembly 90 to define the dispenser well 18 and formthe dispenser structure 10 for the door panel 12. It is contemplatedthat the dispenser assembly 90 can attach to or connect with the atleast one attachment tab 94 via a mechanical fastener 152 such as abolt, screw, rivet, tab, clasp, or other similar mechanical attachmentfeature 180. The insulating structure 26 of the door panel 12 can alsoinclude an interior breaker member 96 that separates the insulatingcavity 28 from the attachment tabs 94.

Referring again to FIGS. 5-7 , the dispenser assembly 90 that attachesto the inner liner 22 and outer wrapper 24 at the aperture 92 within thecentral portion 34 of the door panel 12 can include a supplementalinterior cavity 100 that includes a supplemental insulating material 102disposed therein. In this manner, the dispenser assembly 90 can form aseparate self-contained and insulated module 104 that can bemechanically fastened to the door panel 12 at the various attachmenttabs 94 of the insulating structure 26.

The separate dispenser assembly 90 can include a foam-type insulation asthe supplemental insulating material 102. It is also contemplated thatthe dispenser assembly 90 can be a separate vacuum insulated structurehaving the supplemental interior cavity 100 that is maintained at an atleast partial vacuum 32.

Referring again to FIGS. 5-7 , the various attachment tabs 94 of theinsulating structure 26 for the door panel 12 can include at least oneliner attachment tab 110 that extends from the inner liner 22 and atleast one wrapper attachment tab 112 that extends from the outer wrapper24. The liner and wrapper attachment tabs 112 can include a singleperimetrical flange that extends around the aperture 92 defined withinthe central portion 34 of the door panel 12. It is also contemplatedthat the liner attachment tab 110 can include a plurality of separateattaching members that are placed about the aperture 92 and extend fromthe inner liner 22. Similarly, the wrapper attachment tabs 112 caninclude a plurality of individual members that extend from the outerwrapper 24 and allow for attachment of the dispenser assembly 90 withinthe aperture 92 of the door panel 12. In attaching the separatedispenser assembly 90 to the attachment tabs 94 of the door panel 12, aseal or gasket can be disposed between these members to create a sealbetween the dispenser assembly 90 and the door panel 12. The seal orgasket can define a physical seal and a thermal seal that substantiallyprevents infiltration of fluid and heat through the door panel 12.

Referring again to FIGS. 1-7 , the door panel 12 for the refrigeratingappliance 20 can include the inner liner 22 that is coupled with theouter wrapper 24 to define the insulating cavity 28 therein. An interiorperimeter 120 is defined at least within the outer wrapper 24. Thisinterior perimeter 120 is configured to define an opening 122 for thedispenser well 18 of the dispenser structure 10. An insulating material30 is defined within the insulating cavity 28 and the insulating cavity28 is typically maintained at an at least partial vacuum 32. Thedispenser structure 10 is disposed proximate to the interior perimeter120 and the dispenser structure 10 defines an insulated dispenserportion 36 therein. This insulated dispenser portion 36 is defined bythe interior areas 42 of the dispenser structure 10 defined between theouter structural members of the dispenser structure 10.

In the case of the deep-drawn configuration of the door panel 12,exemplified in FIGS. 3 and 4 , the insulated dispenser portion 36 isintegral with the remainder of the insulating cavity 28 of the doorpanel 12.

In the aspects of the device exemplified in FIGS. 5-7 , where thedispenser assembly 90 is attached, mechanically, to the remainder of thedoor panel 12 at the aperture 92, the insulated dispenser portion 36 isdefined within an outer enclosure 130 of the dispenser assembly 90.Within this outer enclosure 130, the supplemental insulating material102 is disposed therein to define the insulated dispenser structure 10.The dispenser structure 10 also includes the external dispensing cavity44, such as the dispenser well 18, that is defined within the interiorperimeter 120, and extends rearward of the interior perimeter 120 withinthe door panel 12. For accessing the external dispensing cavity 44 ordispenser well 18, a user of the appliance 20 will reach through theinterior perimeter 120 and into the dispenser well 18 for engaging thevarious dispensing functions of the appliance 20. The dispenser conduit40 extends from an interior area 42 disposed above the dispenserstructure 10 to the external dispensing cavity 44 or dispenser well 18.In this manner, the dispenser conduit 40 passes through the insulateddispenser portion 36 of the dispenser structure 10.

Referring again to FIGS. 1, 2 and 5-7 , the interior perimeter 120 isconfigured to define an internal aperture 92 through which the dispenserwell 18 is accessed by a user during operation of the appliance 20. Invarious aspects of the device, an attachment structure 140, typicallyincluding the various attachment tabs 94, is used to attach thedispenser assembly 90 to the remainder of the door panel 12 via theattachment structure 140. This attachment structure 140 can be integralwith the inner liner 22 and outer wrapper 24 to form the various linerattachment tabs 110 and wrapper attachment tabs 112. It is alsocontemplated that the attachment structure 140 can be a separateretaining assembly 142 (shown in FIG. 7 ) that is disposed within theaperture 92 and can be coupled to each of the inner liner 22, the outerwrapper 24 and various portions of the dispenser assembly 90. Asdiscussed above, the attachment structure 140 can include the variousfastening portions 144 that allow for connection between the door panel12 and the dispenser structure 10 or dispenser assembly 90 viamechanical fasteners 152. In various aspects of the device theattachment structure 140 can include a magnetic attachment mechanism. Insuch an embodiment, the dispenser assembly 90 can be attached to,connected with or otherwise coupled to the door panel 12 via a pluralityof magnetic members or a combination of magnetic members andferromagnetic members.

Referring again to FIGS. 5-7 , the attachment structure 140 includesvarious fastener receptacles 150 that are configured to receive thefasteners 152 for attaching the dispenser assembly 90 to the attachmenttabs 94. These fastener receptacles 150 are configured to receive themechanical fasteners 152, and at the same time, are configured tomaintain each of the fasteners 152 separate from the insulating cavity28 of the door panel 12 and, where included, the separate dispenserassembly 90. In this manner, the fastener receptacles 150 can be in theform of attachment portions having internal openings 154 that areconfigured to receive the mechanical fasteners 152. These internalopenings 154 also hold the mechanical fasteners 152 in a predefinedlocation and prevent puncture infiltration, or other undesirablemovement of the various fasteners 152 into the insulating cavity 28 inthe door panel 12 or the supplemental interior cavity 100 of thedispenser assembly 90, where included.

Referring again to FIGS. 3-7 , the dispenser structure 10 that at leastpartially forms the dispenser well 18 includes an external portion 158for defining the external dispensing cavity 44 or dispenser well 18.According to various aspects of the device, this external portion 158that defines the external dispensing cavity 44 can be in the form of theouter wrapper 24. In this manner, the outer wrapper 24, in thedeep-drawn configuration, can be a single continuous piece that definesthe front surface 160 of the door panel 12. Similarly, the dispenserstructure 10 can include an internal portion 162 that at least partiallydefines the interior area 42 disposed above the dispenser structure 10.In various embodiments, the internal portion 162 is a portion of theinner liner 22. Again, in such an embodiment, the inner liner 22 can bea deep-drawn member that forms a single and continuous piece thatdefines the interior surface 164 of the door panel 12. These deep-drawnmembers, in the form of the inner liner 22 and outer wrapper 24 can beconnected together and the dispenser conduit 40 can be attached at thedispenser conduit 40 by the interior trim breaker 52.

Referring now to FIGS. 1-8 , having described various aspects of thedispenser structure 10 for the door panel 12 of the appliance 20, amethod 400 is disclosed for forming a door panel 12 for an appliance 20.The method 400 can include a step 402 for forming a vacuum insulatedstructure having the inner liner 22 and the outer wrapper 24. In formingthis vacuum insulated structure, the inner liner 22 and outer wrapper 24are sealed to form a sealed internal aperture 92 that extends throughthe inner liner 22 and the outer wrapper 24. This internal aperture 92is typically positioned within a central portion 34 of the door panel12. It is contemplated that the central aperture 92 can also bepositioned in an offset configuration toward one of the edges of thedoor panel 12 or can be placed within the central portion 34 of the doorpanel 12 itself. After forming the vacuum insulated structure, thedispenser structure 10 is attached to the vacuum insulated structure atthe sealed internal aperture 92 (step 404). The sealed internal aperture92 includes a plurality of attachment tabs 94 that extend from the innerliner 22, the outer wrapper 24, or each of the inner liner 22 and outerwrapper 24. The dispenser structure 10 is then secured to the pluralityof attachment tabs 94 via mechanical fasteners 152 (step 406). Asdiscussed above, where the plurality of attachment tabs 94 includevarious fastener receptacles 150 that receive corresponding fasteners152, the fastener receptacles 150 maintain each corresponding fastener152 separate from the insulating cavity 28 of the vacuum insulatingstructure 26. Accordingly, these fastener receptacles 150 serve toprevent punctures or other damage to the door panel 12 that might causean infiltration of gas 190 into the insulating cavity 28.

Referring to FIG. 5 , the fastener receptacles 150 can be disposedwithin an area defined between the inner liner 22 and outer wrapper 24,and also between the members of the outer enclosure 130 for thedispenser assembly 90. When the dispenser assembly 90 is attached to theinner liner 22 and outer wrapper 24, the fastener receptacles 150 may beat least partially positioned between this interface. It is alsocontemplated that the fastener receptacles 150 can be positioned nearthe inner liner 22 so that these fastener receptacles 150 aresubstantially concealed by various trim members, or the variousdispenser assemblies of the appliance 20. The various fastenerreceptacles 150 are designed to not be shown within the dispenser well18 during use of the appliance 20.

As exemplified in FIG. 5 , the dispenser assembly 90 includes a wrapperchannel 64 and a liner channel 60 that at least partially surrounds theinterior wrapper edge 66 and the interior liner edge 62 of the outerwrapper 24 and inner liner 22, respectively. The fastener receptacles150 can be at least partially disposed within the wrapper channel 64 andliner channel 60 of the dispenser assembly 90. This placement of thefastener receptacles 150 serves to at least partially conceal thefastener receptacle 150 and the mechanical fastener 152 disposedtherein. The fastener receptacles 150 can also be integrally formed intothe inner liner 22, the outer wrapper 24, or the dispenser assembly 90.

As exemplified in FIG. 6 , the dispenser assembly 90 can include anenclosure having a back wall 170, four side walls 172 and a front wall174. The fastener receptacle 150 can be positioned within a portion of afront wall 174 and the dispenser conduit 40 in the position from the topwall. The dispenser conduit 40 may also be located in the back wall 170or one of the side walls 172. The dispenser assembly 90, in thisconfiguration, can form a substantially self-contained dispenserassembly 90 that can be attached to the various attachment tabs 94 ofthe door panel 12 through the use of the fastener receptacles 150.

In various aspects of the device, as exemplified in FIGS. 1, 2 and 5-7 ,various components of the dispenser systems 74 for the appliance 20 canbe incorporated within the dispenser assembly 90. By way of example, andnot limitation, the dispenser assembly 90 may include attachmentfeatures 180 for connecting a water dispensing assembly 14, an icemaking assembly 16, the various operating paddles 72, a user interface182, and other similar mechanisms that are typically attached proximatethe dispenser well 18 of an appliance 20. It is also contemplated thatthe dispenser assembly 90 can include an integrated ice making assembly16, various water dispensing assemblies 14, paddles 72, and otherdispensing features of the various dispensing systems for the appliance20. In such an embodiment, the dispenser assembly 90 can be attached tothe remainder of the door panel 12 as a self-contained unit. Duringfinal manufacture, electrical wiring, data cabling, fluid lines, andother similar services can be attached to the dispenser assembly 90 formaking the dispenser assembly 90 operational during use.

Referring now to FIGS. 1-7 and 9 , having described various aspects ofthe device, a method 500 is disclosed for forming a door panel 12 of anappliance 20. This method 500 can include step 502 of deep drawing aninner liner 22 to define an interior portion of a dispenser structure10. Step 504 can include deep drawing an outer wrapper 24 to define anexternal portion 158 of the dispenser structure 10. The inner liner 22and outer wrapper 24 can be attached together to define a continuousinsulating cavity 28 for the door panel 12 (step 506). In such anembodiment, the continuous insulating cavity 28 also extends through thedispenser structure 10. According to the method 500, an internal trimbreaker can be attached to the inner liner 22 and outer wrapper 24 toform a dispenser conduit 40 through the dispenser structure 10 (step508). The interior trim breaker 52 is configured to extend between theinterior and exterior portions of the dispenser structure 10. In thismanner, the interior trim breaker 52 is attached to each of the innerliner 22 and outer wrapper 24 for the door panel 12. According to themethod 500, at least a portion of the gas 190 from the continuousinsulating cavity 28 is evacuated to define a vacuum insulatingstructure 26 (step 510). This vacuum insulating structure 26 extendsthrough the entire interior insulating cavity 28, including thesupplemental interior cavity 100 of the dispenser structure 10. In suchan embodiment, the insulating cavity 28 is defined by the inner liner22, the outer wrapper 24 and the interior trim breaker 52.

According to various aspects of the device, the dispenser structure 10that is attached to the door panel 12 can be incorporated within variousappliances 20. Such appliances 20 can include, but are not limited to,refrigerators, freezers, laundry appliances, dishwashers, ovens, smallappliances, and other similar residential and commercial appliances andfixtures.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connectors or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above aremerely for illustrative purposes and not intended to limit the scope ofthe device, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

What is claimed is:
 1. A door panel for a refrigerating appliance, thedoor panel comprising: an inner liner; an outer wrapper attached to theinner liner and defining an insulating structure with an insulatingcavity disposed therein; an insulating material defined within theinsulating cavity; a dispenser structure defined within a portion of theinner liner and the outer wrapper, wherein the dispenser structuredefines an insulated dispenser portion therein, wherein the insulatingcavity is a single and continuous cavity that extends between the innerliner and the outer wrapper and through the insulated dispenser portionof the dispenser structure; and a dispenser conduit defined by aninterior trim breaker that extends from an interior area disposed abovethe dispenser structure to an external dispensing cavity and passingthrough the insulated dispenser portion, wherein the inner liner and theouter wrapper includes a deep-drawn portion that defines the dispenserstructure, wherein the inner liner and the outer wrapper each include arespective upturned flange that is directed away from the externaldispensing cavity, the dispenser conduit having a liner channel thatengages the respective upturned flange of the inner liner and a wrapperchannel that engage the respective upturned flange of the outer wrapper,and wherein the wrapper channel has a diameter that is smaller than therespective upturned flange of the inner liner to pass through the innerliner and engage the respective upturned flange of the outer wrapperwithin the insulating cavity.
 2. The door panel of claim 1, wherein theinterior trim breaker is fixedly coupled with the inner liner and theouter wrapper at the dispenser structure.
 3. The door panel of claim 2,wherein the interior trim breaker is disposed within the deep-drawnportion of the inner liner and the outer wrapper.
 4. The door panel ofclaim 1, wherein the insulating cavity is further defined by theinterior trim breaker, and wherein the insulating cavity includes theinsulated dispenser portion.
 5. The door panel of claim 1, wherein theinsulating cavity defines an at least partial vacuum.
 6. The door panelof claim 1, wherein the dispenser structure includes an external portionthat at least partially defines the external dispensing cavity.
 7. Thedoor panel of claim 6, wherein the external portion is defined by theouter wrapper.
 8. The door panel of claim 1, wherein the dispenserstructure includes an internal portion that at least partially definesthe interior area disposed above the dispenser structure, and whereinthe internal portion is defined by the inner liner.